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Winding a Uniform Roll in Converting Winders

OUR DESIGN EXPERTISE


Our design expertise covers the entire range of a tissue winding steps to designing a complete winding line for tissue or other specific needs. The range of materials to be wound includes tissue, towel, non woven, gauze, laminates, wipers, etc. We specialize in the Design of Cams, especially for the winding process cams for center as well as surface winders; and cams for reciprocating motions involved in wrappers, case packers and bundlers.


MACHINERY DEVELOPMENT


Starting from concept, we engage in prototype development, followed by engineering, design (CAD) and manufacture of the complete production machine.

In addition to the machines designed and manufactured according to the patents listed below,
other machines include

Complete winding line for Kitchen Towel with a proprietary winder and a wrapper;
Winders for specialty items such as absorbent pads, gauzes and non wovens.
Single roll paper wrapper rated at 105 rolls per minute.


DESIGN OF WINDING CAMS


Given the product specifications, compute the profile of the winding cam, as NC code for milling the metal cam. Alternatiely, convert the profile into a table of values for a soft cam.

  1. Meter-winding cam for PCMC 150, and PCMC 200 series continuous winders.
  2. Diatrol cam for Perini and other Surface Winders.
  3. Cams for any non-standard winder.
Method of Solution

Given the winder geometry and product specifications, develop the kinematic formulas to wind a perfect Archimedean Spiral. In case of center winders, the formulation includes contributions of turret swing and indexing, and the epicyclic action of the serpentine belt.

In the case of surface winders, it involves the contribution due to moving contact points in the winding nest.

Computer Programs


"MW150H" calculates the winding table and N-C code for creating the cone pulley cam.
"MW150S" generates the winding table suitable for any electronic drive.
"MW200H" calculates the winding table and N-C code for steel cam for older 200 winders.
"MW200S" generates the winding table for soft cam for Series 200 and later winders.
"SURFAC" calculates the winding table for Diatrol cam controlled Perini Winders
"DIATRL" designs the Diatrol cam and develops the N-C milling code
The above programs are modified to handle alternative geometries.

Input

  1. Scale drawing of the winder geometry in the winding area.
  2. Product specifications.
Measure of Success

  1. The wound rolls will exhibit improved uniformity from start to finish.
  2. Sheet breaks would be reduced in center winders.
  3. In case of surface winders, the hard ring near the core will be alleviated.
  4. Need to overcount in surface winders would be minimal.
  5. The winders should pick up speed, and run steadily.
Case Histories

  • In through-dry (TAD) process, the above method increased the throughput by as much as 5%.
  • In light-dry-crepe (LDC) process, the speed of the winders in converting increased by about 50-100  fpm.
  • In heavy-wet-crepe (HWC) process, perf breaks and wrap-ups were reduced.
  • In a surface winder for 2-ply towel, the sheet count was reduced by 5 to make the same diameter roll, and the quality of winding matched a center winder. 
  • In a surface winder, by redesigning the Diatrol linkage, the controls for core diameter and full roll diameter were uncoupled.

PATENTS: WINDING MACHINERY

US 6,425,547, Jul 30, 2002, System and Method for Producing Coreless Fabric Rolls: A system for winding coreless non-woven/gauze bandage rolls.

WO 2010/133037, Nov 25, 2010: Method and Rewinding Machine for Winding Paper around Core: A rewinding machine for winding rolls of tissue/towel paper.

US 4,265,409, May 5, 1981, Web Rewinder Turret Swing Control*: An apparatus that controls the swinging frame and rotation of a turret in a web rewinder.

US 4,009,814, Mar 1, 1977, Web Accumulator: A device for accumulating and discharging a reserve portion of a continuous web.



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